Foreign Object Damage Prediction in Ceramic Matrix Composites

The combined effects of CMAS (calcium magnesium aluminosilicate) and FOD (foreign object damage) were determined in three different ceramic matrix composites (CMCs), two melt-infiltrated (MI) SiC/SiCs and one oxide/oxide. Foreign object damage was introduced at ambient temperature in CMC test targets using 1.6 mm steel ball projectiles at an impact velocity of 340 m/s utilizing a ballistic impact gun. One type of target support, partial support, was used. The impact-damaged test coupons were then CMAS-exposed at 1200°C for 10 hrs in air. Additional tests were also performed by exposing impact-damaged test coupons to a mixture of CMAS and salt (sodium sulfate) at 1200°C for 10 hrs in air. The combined effects of FOD and CMAS or CMAS/salt were quantified by determining the residual strengths of test coupons after exposures. Also, six different sands ingested into aeroengines were analyzed in their chemical compositions. The melt CMAS solid, melted at 1300°C and solidified, was assessed in its mechanical properties of microhardness and fracture toughness.

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Development and Evaluation of Foreign Object Damage Resistant Ceramic Matrix Composites

Volume 6: Ceramics; Controls, Diagnostics and Instrumentation; Education; Manufacturing Materials and Metallurgy ◽

10.1115/gt2017-64944 ◽

2017 ◽

Author(s):

Craig Iwano ◽

Brian Sullivan ◽

Michelle Hoo Fatt

Keyword(s):

Ceramic Matrix Composites ◽

Ceramic Matrix ◽

Experimental Program ◽

Matrix Composites ◽

Foreign Object ◽

Foreign Object Damage ◽

Sic Fiber ◽

Materials Research ◽

Computational Materials ◽

The Impact

Under a Phase II Navy SBIR program, Materials Research & Design (MR&D) performed an integrated analytical, fabrication and experimental program in order to develop foreign object damage (FOD) resistant silicon carbide (SiC) fiber-based ceramic matrix composites (CMCs), specifically 2D tape SiC/SiC. MR&D believes strongly that the most efficient approach towards the development of FOD-resistant CMCs is to develop a mathematical simulation of the impact event which can be correlated to measured responses and observed failures. Once correlated with available test data, the developed math model was used as part of an Integrated Computational Materials Engineering (ICME) approach to analytically investigate modifications to baseline CMC material in an attempt to identify which properties best influenced FOD resistance. The best candidate material modifications were then selected for fabrication and experimental validation. When considering all of the numerical and empirical data (visible damage, rebound velocity (energy absorption), strain data, NDE inspection and residual strength testing), all of the MR&D-proposed material modifications demonstrated improved FOD resistance when compared to the baseline CMC material.

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Quantification of Foreign Object Damage and Electrical Resistivity for Ceramic Matrix Composites and Tensile Residual Strength Prediction

Journal of Engineering for Gas Turbines and Power ◽

10.1115/1.4028677 ◽

2015 ◽

Vol 137 (5) ◽

Cited By ~ 4

Author(s):

Frank Abdi ◽

Gregory N. Morscher ◽

Yibin Xue ◽

Sung Choi

Keyword(s):

Electrical Resistivity ◽

Residual Strength ◽

Fiber Strength ◽

Ceramic Matrix Composites ◽

Ceramic Matrix ◽

Matrix Composites ◽

Foreign Object ◽

Foreign Object Damage ◽

Transverse Tensile ◽

Damage States

SiC-based ceramic matrix composites (CMC) in turbine engine applications must sustain certain foreign object impacts (FOIs) that might occur in services. Experiments and nondestructive evaluation (NDE) have illustrated good correlations between impact energy and foreign object damage (FOD) assessed using electrical resistivity (ER), acoustic emission (AE), and microscopy. A progressive failure dynamic analysis (PFDA) method is explored in understanding and predicting the damage states, ER, and residual strength after impact of CMCs. To accurately correlate the damage state with ER, the PFDA tool has been improved to incorporate the physical damage mechanisms in CMCs, which are matrix microcrack density due to both longitudinal and transverse tensile loads and the fiber breakage due to probabilistic fiber strength distribution. The predicted damage states and ER are correlated with the measurement of FOD and validated with tension after impact tests using high temperature ER. The PFDA tool has demonstrated a great potential for CMCs' FOD and residual strength predictions.

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Foreign Object Damage in 3-D Woven SiC/SiC Ceramic Matrix Composites of Varying Architectures at Ambient and High Temperatures

Volume 6: Ceramics; Controls, Diagnostics and Instrumentation; Education; Manufacturing Materials and Metallurgy ◽

10.1115/gt2017-63475 ◽

2017 ◽

Cited By ~ 3

Author(s):

Michael J. Presby ◽

Gregory N. Morscher ◽

Craig Iwano ◽

Brian Sullivan

Keyword(s):

High Temperatures ◽

Ceramic Matrix Composites ◽

Matrix Composites ◽

Foreign Object ◽

Micro Computed Tomography ◽

Foreign Object Damage ◽

Sic Ceramic ◽

Post Impact ◽

Sic Composites ◽

Non Destructive

Foreign object damage (FOD) behavior in 3-D woven SiC/SiC composites of three different fiber architectures were characterized at ambient (21 °C) and high temperatures (1100 °C) using tungsten carbide projectiles impacted at approximately 350 m/s. Non-destructive evaluation (NDE) techniques such as electrical resistance (ER) and micro-computed tomography (micro-CT) were used to evaluate and compare the damage morphologies of the different architectures. Post-impact retained strength was also conducted using a four point flexural test while utilizing acoustic emission (AE) and ER to monitor the damage accumulation.

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